Operation and Maintenance of Offshore Cranes API RECOMMENDED PRACTICE 2D SEVENTH EDITION, DECEMBER 2014 ERRATA, AUGUST 2015 Special Notes API publications necessarily address problems of a general nature With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed Neither API nor any of API's employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication Neither API nor any of API's employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights API publications may be used by anyone desiring to so Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict API publications are published to facilitate the broad availability of proven, sound engineering and operating practices These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard API does not represent, warrant, or guarantee that such products in fact conform to the applicable API standard Users of this Recommended Practice should not rely exclusively on the information contained in this document Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein All rights reserved No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005 Copyright © 2014 American Petroleum Institute Foreword This recommended practice is under the jurisdiction of the API Subcommittee on Drilling and Production Operations and was developed in cooperation with the Offshore Operators Committee Detailed requirements for the design and construction of offshore cranes are given in API 2C The principles provided herein on the operation, inspection and maintenance of offshore cranes are based in part on an understanding of the cranes’ design and construction Therefore, this document should be used in conjunction with API 2C Conformance to the intent of the programs and practices recommended herein is intended to result in cranes that operate safely and efficiently between inspection periods and in accordance with a company's safety and environmental management system (see API 75) Each crane owner, qualified crane operator, qualified inspector, and qualified rigger is encouraged to follow the recommendations outlined herein, and to modify or supplement them with any practices or procedures which are more appropriate for the type and duty cycle-both past and future-of the crane, provided the minimum recommendations and the intent of the programs stated herein are met The material in this publication represents the contribution of industry representatives of crane users, crane manufacturers, wire rope manufacturers and ancillary crane device or component manufacturers It is based on industry experience and expertise involving worldwide operations It should be understood that the crane operating and maintenance practices cover a wide range of crane types and configurations Not all practices are applicable to all cranes When applying this document, care should be taken to review each item as stated, and use those items specifically applicable to the crane's type, usage, and duty-cycle It may be necessary to modify a procedure due to a particular crane requirement This modification would be wholly acceptable as long as the original intent of the practice or procedure is met The verbal forms used to express the provisions in this specification are as follows: — the term “shall” denotes a minimum requirement in order to conform to the specification; — the term “should” denotes a recommendation or that which is advised but not required in order to conform to the specification; — the term “may” is used to express permission or a provision that is optional; — the term “can” is used to express possibility or capability Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005 Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years A one-time extension of up to two years may be added to this review cycle Status of the publication can be ascertained from the iii API Standards Department, telephone (202) 682-8000 A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005 Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standards@api.org iv Contents Page Scope Normative References 3.1 3.2 Terms, Definitions, and Abbreviations Terms and Definitions Abbreviations 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Operation Crane Operator and Rigger Qualifications and Operating Practices Handling the Load 11 Signals 12 Personnel Transfer 13 Refueling 13 Fire Extinguishers 13 Load Test 13 Pull Test 17 5.1 5.2 5.3 5.4 5.5 5.6 Inspection, Testing, and Maintenance Usage and Inspection Inspection and Load Test Records Maintenance Lubrication Crane Rerating Crane Derating 17 17 19 20 21 21 21 6.1 6.2 6.3 Wire Rope and Sling Inspection, Maintenance, and Replacement General Wire Rope Slings 22 22 22 24 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 Lift Planning General Roles and Responsibilities Planning the Lift Lift Categorization Risk Assessment Personnel Transfer Personnel Qualifications Documentation of a Lift Plan Approval of Lift Plans Changes to lift Plans Summary Questions for a Safe Lift 25 25 26 27 29 29 30 30 30 31 31 31 8.1 8.2 8.3 Personnel Training Qualifications Qualified Rigger Qualified Crane Operator Qualified Crane Inspector 31 31 32 32 Contents Page 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 Temporary Crane Installation Planning the Installation Installing the Temporary Cranes Testing and Inspecting the Installation Usage Crane Design Crane Equipment Load Test Requirements Preventative Maintenance Work History Rental Checklist Tie-down Weld Design Torque Procedure Weld Procedure Load Test Load Test Procedure Inspection of Temporary Cranes after Installation 32 32 33 33 33 34 34 35 35 36 36 36 36 37 37 37 37 Annex A (informative) Crane Operation 38 Annex B (informative) Usage, Inspection, Testing, and Maintenance 40 Annex C (informative) Crane-assisted Personnel Transfer 51 Annex D (normative) Load Testing 57 Annex E (informative) Crane Maintenance 61 Annex F (normative) Wire Rope and Sling Inspection, Maintenance, and Replacement 62 Annex G (informative) Lift Categories 76 Annex H (normative) Training 79 Annex I (informative) Loading and Unloading Offshore Support Vessels 117 Bibliography 120 Figures Standard Hand Signals for Controlling Crane Operations Usage/Inspection/Inspector Qualification Matrix B.1 Tilt Method B.2 Depression Measurement Method B.3 Rotation Method D.1 Capacity vs Radius for a Typical Crane D.2 Example of a Typical Load Chart F.1 Three Basic Components of Wire Rope F.2 Showing Distance of One Rope Lay F.3 Measurement-Diameter F.4 Core Failures in Rotation-Resistant Wire Rope F.5 Valley Breaks 14 20 46 47 48 57 58 62 63 64 65 65 Contents Page F.6 F.7 F.8 F.9 F.10 F.11 H.1 H.2 H.3 H.4 H.5 H.6 H.7 H.8 H.9 H.10 H.11 H.12 Right and Wrong Way to Measure Wire Rope Diameter 67 Transferring Rope from Reel to Drum 69 Method of Installing Wedge-socket Attachment 71 Choker Configuration 73 Rated Sling Capacity Calculation Example (Included Angle) 73 Rated Sling Capacity Calculation Example (Horizontal Angle) 74 Pre-lift Rigging Hardware and Sling Testing Form 86 Rigging Hitches Testing Form 90 Hand Signal Testing Form 93 Qualified Rigger Card Example 93 Pre-use Daily Inspection Testing Form 99 Pre-use Inspection Checklist 100 Hand Signal Testing Form 102 On-board (Static) Lift Procedures Testing Form 107 Off-board (Dynamic) Lift Procedures Testing Form 108 Blind Lift Procedures Testing Form 109 Blind Lift Procedures Example Certificate 110 Crane Inspector Example Certificate 116 Table Static/Onboard Test Load and Radius 16 Operation and Maintenance of Offshore Cranes Scope 1.1 This recommended practice establishes general principles for the safe operation and maintenance of offshore pedestal-mounted revolving cranes on fixed or floating offshore platforms, offshore support vessels, jackup drilling rigs, semi-submersible drilling rigs and other types of mobile offshore drilling units (MODUs) This document also provides requirements and recommendations for personnel training, lift planning, preuse inspection, and testing of temporary cranes that are erected offshore 1.2 Typical applications can include, but are not limited to the following a) Offshore oil exploration and production applications; these cranes are typically mounted on a fixed (bottom-supported) structure, floating platform structure, or ship-hulled vessel used in drilling and production operations for offshore minerals and energy b) Shipboard applications; these lifting devices (rated for 10,000 lbs [4536 kg] or more) are mounted on surface-type vessels and are used to move materials, containers, ROVs, diving bells, pipeline, subsea components, and other materials on the vessel, between vessels, into the sea, or to the sea bed c) Heavy-lift applications; cranes for heavy-lift applications are mounted on barges, self-elevating vessels or other vessels, and are used in construction and salvage operations above and below the sea surface 1.3 Equipment (e.g davits, launch frames) used only for launching life-saving appliances (life boats or life rafts) are not included in the scope of this recommended practice 1.4 Lifting devices not covered by this document should be operated, inspected, and maintained in accordance with the manufacturer’s recommendations Normative References The following referenced documents are indispensable for the application of this document For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies API RP 2A-WSD, Recommended Practice for Planning, Designing and Constructing fixed Offshore Platforms−Working Stress Design API Spec 2C, Offshore Pedestal-mounted Cranes API Spec 9A, Specification for Wire Rope API RP 9B, Application, Care and Use of Wire Rope for Oil Field Service ASME 1, B30.9, Slings AWS 2, D1.1, Structural Welding Code—Steel WRTB 3, Wire Rope Sling User’s Manual ASME International, Park Avenue, New York, NY 10016-5990, www.asme.org American Welding Society, 8669 NW 36 Street, #130, Miami, Florida 33166-6672, www.aws.org API RECOMMENDED PRACTICE 2D WRTB, Wire Rope User’s Manual WSTDA RS-1 4, Recommended Standard for Synthetic Polyester Roundslings WSTDA WS-1, Recommended Standard for Synthetic Web Slings 3.1 Terms, Definitions, and Abbreviations Terms and Definitions For the purposes of this document, the following definitions apply 3.1.1 authorized surveyor A person who works for a third-party certifying authority who is hired to inspect the crane 3.1.2 auxiliary hoist line whip line A secondary hoist rope (if present) on a crane 3.1.3 anti-two-blocking A means to protect hoist ropes, structural components, and machinery from damage that can occur when two sheave groups (e.g load block and boom tip) come into contact as the hoist cable is drawn in 3.1.4 bearing raceway The surface of the bearing rings which contact the rolling element (balls or rollers) of the swing-bearing assembly 3.1.5 boom A member hinged to the revolving upper-structure and used for supporting the hoist tackle 3.1.6 boom angle The angle above or below horizontal of the longitudinal axis of the base boom section 3.1.7 boom angle indicator An accessory that indicates the angle of the boom above horizontal 3.1.8 boom hoist A mechanism responsible for raising and lowering the boom 3.1.9 boom length The straight-line distance from the centerline of boom foot-pin to the centerline of the boom-point main load hoist sheave pin, measured along the longitudinal axis of the boom Wire Rope Technical Board, 7011A Manchester Blvd., #178, Alexandria, VA 22310-3203, www.wireropetechnicalboard.org Web Sling Tie Down Association, 2105 Laurel Bush Road, Suite 201, Bel Air, MD 21015, www.wstda.com 108 API RECOMMENDED PRACTICE 2D TASK Lift Procedures Lift #2 Off-board (Dynamic) Circle One: Pass Fail Name: _ Date: Print The examiner and student will sign the practical exercise form The student signing the practical exercise form validates he/she has acceptable understanding and knows his/her responsibilities Student participated in the (group) pre use Inspection Pass Fail Lift Plan on hand Pass Fail Verify the Entry/Exit (before starting): Pass Fail Verify the weight of the load: Pass Fail Check interpretation of load chart: Pass Fail Determine if the load is safe or not safe to lift: Pass Fail Centering the ball or load block over the load: Pass Fail Verify tag line on load: Pass Fail Testing the winch brakes: Pass Fail 10 Clearing all obstacles: Pass Fail 11 Lifting load over personnel: Pass Fail 12 Watch for overturning moment (overload): Pass Fail 13 Watch for two-blocking Pass Fail 14 Control of the load: Pass Fail 15 Dragging the load (sideloading): Pass Fail 16 Load contacting any part of the course: Pass Fail 17 Check depth perception to see if place at position #3 Pass Fail Comments: _ _ _ _ _ Student Signature _ Examiner Signature Figure H.9—Off-board (Dynamic) Lift Procedures Testing Form OPERATION AND MAINTENANCE OF OFFSHORE CRANES 109 TASK Lift Procedures Lift #3 Blind Circle One: Pass Fail Name: _ Date: _ Print The examiner and student will sign the practical exercise form The student signing the practical exercise form validates he/she has acceptable understanding and knows his/her responsibilities Student participated in the (group) pre use Inspection: Pass Fail Lift Plan on hand: Pass Fail Verify the Entry/Exit (before starting): Pass Fail Verify the weight of the load: Pass Fail Check interpretation of load chart Pass Fail Determine if the load is safe or not safe to lift: Pass Fail Centering the ball or load block over the load: Pass Fail Verify tag line on load: Pass Fail Testing the winch brakes: Pass Fail 10 Clearing all obstacles: Pass Fail 11 Lifting load over personnel: Pass Fail 12 Watch for overturning moment (overload): Pass Fail 13 Watch for two-blocking: Pass Fail 14 Control of the load: Pass Fail 15 Dragging the load (sideloading): Pass Fail 16 Load contacting any part of the course: Pass Fail 17 Interpretation of Hand Signals Pass Fail Comments: _ Student Signature _ Examiner Signature Figure H.10—Blind Lift Procedures Testing Form 110 API RECOMMENDED PRACTICE 2D Front Side (Crane Operator) (Company Name Here) (Company Address Here) COMPANY LOGO (Company Phone/Fax Number Here) Qualified Crane Operator (First Name Here) (Last Name) (Last four ID #) The individual named above, has satisfactorily demonstrated necessary skills through written, practical, oral evaluation and has successfully completed the course of instruction as prescribed for (Course Title Here) in accordance with latest edition of the API RP2D Expires: _ / _/ _ Date Instructor/Examiner: Name Back Side (Crane Operator) CRANE OWNER’S NOTES: It is advised that all crane owners give due consideration to the following when requiring the use of a Qualified Crane Operator The crane owner shall be responsible for Qualified Crane Operator Qualifications requirements to be met in accordance with API RP2D latest edition Check Box No history of a disabling medical condition, which can be sufficient reason for disqualification Any corrective lenses required Crane Type Qualified to Operate Mechanical Friction Hydraulic Non-Mechanical Electrical Tracking No: Figure H.11—Blind Lift Procedures Example Certificate OPERATION AND MAINTENANCE OF OFFSHORE CRANES 111 H.4 Crane Inspector Training H.4.1 General Crane inspector training is a critical part of the prevention of crane accidents due to component failure Training shall reference a formalized, written training program An outline of the major items that should be included in this training program is listed In addition to the recommended training elements for Qualified Crane Operators the inspector training program shall be tailored to the particular cranes or crane types for which the inspector is to be qualified H.4.2 Qualified Crane Inspector Training H.4.2.1 Important part of crane safety is proper training of inspectors Training shall incorporate familiarization on crane maintenance, troubleshooting, inspecting, JSAs/JSEAs, and lift plan H.4.2.2 a) b) Maintenance and troubleshooting of non-mechanical functions to include: — hydraulic, — electric Maintenance and troubleshooting of mechanical functions (friction) H.4.2.3 a) Qualified Crane Inspectors shall be trained as follows on the type of cranes they will inspect The following shall be included as requirements for inspector training Classroom-type sessions with written and hands-on examinations on the type of crane to be maintain, troubleshot, and inspected by the Qualified Crane Inspector 1) Such classroom-type sessions and examinations shall cover all major crane components; the operational and maintenance procedures appropriate for the type and capacity of crane to be operated; and all major issues and guidelines addressed in this document 2) Training shall also cover hoist overhaul and troubleshooting, structural aspects of offshore canes; knowledge of structural critical components inspection area’s and additionally applicable recognized regulatory compliance requirements b) The Qualified Inspector shall demonstrate by written examination an appropriate understanding of the requirements of this RP c) If a mechanical or non-mechanical crane is to be maintained, troubleshot, or inspected, the necessary experience and training shall be focused on each type of crane classification H.4.2.4 With this minimum training, the Qualified Crane Inspector should be qualified to maintain, troubleshoot, and perform inspections on the crane(s) on which they have been trained H.4.3 Crane Inspector Training Outline H.4.3.1 Course content shall discuss and the appropriate section objectives shall include the following objectives related to API 2C (as applicable) for offshore pedestal mounted cranes as appropriate for the type of crane used The following should be reviewed: a) critical components; b) API 2C definitions; 112 API RECOMMENDED PRACTICE 2D c) crane rated loads; d) crane ratings; e) allowable stresses; f) design authentication and testing; g) critical rigging components; h) boom hoist, load hoist, and telescoping boom hoist; i) swing mechanism; j) power plant; k) controls; l) cabs and enclosures; m) miscellaneous requirements and equipment; n) welding of critically stressed components; o) nondestructive examination of critical components; H.4.3.2 Course content shall include the entire body of information contained within API 2D, API 2C, and the appropriate section objectives shall include the following objectives related to API 2D for offshore pedestal mounted cranes as appropriate for the type of crane used H.4.3.3 Course content shall familiarize students with typical problems encounter in crane maintenance, troubleshooting and inspection for offshore pedestal mounted cranes as appropriate for the type of crane used and knowledge of the following a) Mechanical and non-mechanical cranes (general): 1) load charts/information charts (correct and configure to crane); 2) importance of following manufacturer’s recommendations; 3) safety factors involved; 4) hoists; 5) structural aspects of offshore cranes; 6) structurally critical components; 7) critical inspection areas; 8) recognized applicable regulatory compliance; 9) basic knowledge of NDE such as (dye penetrant procedures); 10) what records are to be reviewed and maintained; 11) how to review completed repair records and status of any open repairs; OPERATION AND MAINTENANCE OF OFFSHORE CRANES 12) knowledge and demonstration of measurement tools; 13) safety systems; 14) prime mover; 15) boom inspection and repair; 16) emergency load lowering procedures (as applicable) b) Non-mechanical (specific basic hydraulic): 1) physical world of hydraulic; 2) hydraulic terminology; 3) transmission of force and energy; 4) simple hydraulic system; 5) basic hydraulic symbols; 6) hydraulic fluid; 7) operation at the suction side of pump; 8) actuators; 9) luffing cylinders; 10) control of hydraulic energy; 11) check valves, accumulators; 12) flow control values; 13) directional control values; 14) pressure control values; 15) pilot operated pressure control valve; 16) different types of pumps; 17) hydraulic motors; 18) reservoirs, coolers, and filters; 19) hydraulic symbols and schematic drawings; 20) knowledge of hoses; 21) hoists; 22) Emergency load lowering procedures (as applicable) 113 114 c) d) API RECOMMENDED PRACTICE 2D Non-mechanical (specific basic electric): 1) electrical symbols and schematic drawings; 2) basic electrical terminology; 3) all applicable motors, controls, and panels; 4) swing limit switch; 5) emergency load lowering procedures (as applicable) Mechanical (specific basic friction): 1) mechanical terminology; 2) swing lock and brake; 3) vertical and horizontal swing shaft and bevel gear boxes; 4) applicable hook roller assemblies 5) upper and lower reduction gear cases ; 6) all hoist planetary brakes and clutches; 7) clutch assemblies; 8) all applicable drum brakes; 9) boom hoist pawl; 10) boom hoist brake; 11) chain case and pump; 12) applicable operational function controls and systems; 13) bearing – gear – shaft and housing inspection; 14) emergency load lowering procedures (as applicable) H.4.4 Practical Exercises and Simulations H.4.4.1 H.4.4.1.1 General A pedestal crane shall be used for practical exercises and testing H.4.4.1.2 Practical exercises shall include the instructions on the proper usage of measuring and testing tools, as specified in relevant recommended practices H.4.4.1.3 Practical exercises shall include identification of stress, corrosion, and inspection practices H.4.4.1.4 The training provider shall maintain a documented requirement for all the hands-on exercises conducted in each course OPERATION AND MAINTENANCE OF OFFSHORE CRANES 115 H.4.4.1.5 The hands on exercises shall include a requirement for covering any failed portions of the hand-on examination immediately after exam completion H.4.4.2 Practical Evaluation H.4.4.2.1 The training provider shall maintain a documented procedure requiring a practical examination with all exercises in crane maintenance, troubleshooting and inspection centered on critical components for offshore pedestal mounted cranes as appropriate for the type of crane used a) b) c) d) Mechanical and non-mechanical cranes (basic general): 1) types of swing assemblies typically used on pedestal-mounted cranes; 2) crane safety systems; 3) wire rope; 4) prime mover; 5) boom inspection; 6) sheave; 7) load and pull test procedures; 8) emergency load lowering Non-mechanical (specific basic hydraulic): 1) hoist tear down and troubleshooting; 2) hoist brake test; 3) emergency load lowering Non-Mechanical (Specific Basic Electric): 1) hook and swing board/panel voltage measurements; 2) emergency load lowering Mechanical (specific basic friction): 1) clutches disassemble/reassemble and adjustments made; 2) boom band brake adjustments; 3) control lever adjustments; 4) Torqmatic converter pressure plate (clutch) adjustment; 5) emergency lowering H.4.4.2.2 Upon completion of the qualified inspector training the Qualified Inspector will be qualified in one of the following: a) mechanical (friction); 116 b) API RECOMMENDED PRACTICE 2D non-mechanical: — hydraulic, — electric H.4.4.2.3 Upon completion of the qualified inspector training the Qualified Inspector will be issued a certificate and card with minimum information required as shown in Figure H.12 on the card and certificate Front Side (Crane Inspector) (Company Name Here) (Company Address Here) COMPANY LOGO (Company Phone/Fax Number Here) Qualified Crane Inspector (First Name Here) (Last Name) (Last four ID #) The individual named above, has satisfactorily demonstrated necessary skills through written, practical, oral evaluation and has successfully completed the course of instruction as prescribed for (Course Title Here) in accordance with latest edition of the API RP2D Expires: _ / _/ _ Date Instructor/Examiner: Name Back Side (Crane Inspector) It is advised that all crane owners give due consideration to the following when requiring the use of a Qualified Crane Inspector The crane owner shall be responsible for Qualified Crane Inspector Qualifications requirements to be met in accordance with API RP2D latest edition CRANE OWNER’S NOTES: Check Box No history of a disabling medical condition, which can be sufficient reason for disqualification Any corrective lenses required Crane Type Qualified to Inspect Mechanical Friction Hydraulic Non-Mechanical Electrical Tracking No: Figure H.12—Crane Inspector Example Certificate Annex I (informative) Loading and Unloading Offshore Support Vessels I.1 Purpose The information in this annex is meant to provide guidance to crane owners and operators for safe operating practices during transfers of personnel or material to and/or from offshore support vessels I.2 Operations I.2.1 Vessel Operations—General I.2.1.1 The master of the vessel is responsible for safe positioning of the vessel during lifting operations and should consult with the facilities Person in Charge (PIC) prior to a lift for details related to positioning During lifting operations, the vessel should maintain station I.2.1.2 In order to prevent spillage over the vessel, or other discharges from interfering with vessel operations, an announcement should be made over public address systems to secure any discharges in way of the vessel involved in conducting lifting operations If discharges from the installation interfere with vessel operations, the loading or unloading operation should cease I.2.2 Lifting Operations—General I.2.2.1 Offboard/dynamic load charts should be used for all lifting operations involving vessels with consideration given to sea conditions and relevant significant wave heights I.2.2.2 Crane operators should not lift loads that exceed the crane’s nominal capacity (Rn) stated in the dynamic load chart I.2.2.3 Crane operators shall maintain visual contact with the load Where this is not possible, crane operators should maintain visual contact with another person who has direct visual contact with the load and direct communication with the crane operator I.2.3.4 Crane operators should know and obey the emergency stop signal at all times I.2.2.5 Loads should never be swung over the wheelhouse or crew on the vessel and should be lifted and lowered over the sea as long as possible before being swung over the boat deck I.3 Communications I.3.1 Two-way radio communication is most important between the vessel master, crane operator, PIC, and designated signalman on the deck of the vessel during marine transfers Whenever possible, vessel deck crew and deck operators on the installation should wear and communicate with radio headsets with integrated microphones that fit on or under required personal protection equipment I.3.3 The PIC and designated signalman should be identified and documented on the lifting plan and be communicated to the lift team and to personnel in proximity of the lift A best practice is to have the designated signalman clearly identified by high visibility vest or hardhat cover that is different from other colors used (e.g red vest for fire watch) 117 118 API RECOMMENDED PRACTICE 2D I.3.4 Signals between the crane operator and the designated signalman should be discernible—audibly or visually—at all times When using radio communication, continuous verbal instructions should be used The crane operator should stop the lifting operation whenever there is no clearly understood signal I.3.5 The effectiveness of communications should be verified, with particular attention given for blind lifts (e.g designated channels on radio for the operation) I.4 Lift Planning I.4.1 Transport documents should be transferred between the installation and the vessel well in advance of the start of lifting operations in order to allow sufficient time for personnel to plan and review the lifting operation material safety data sheets (MSDS) should be provided, when applicable I.4.2 The crane operator, master of the vessel, PIC, designated signalman, and all other involved personnel should carry out a pre-job/toolbox safety meeting including the review of JSA/JSEA documents before the loading or unloading operation commences The talk should include the following: — discussion and review of the cargo manifest; — review and discussion of the crane operation including positioning of load or offload, identification of persons in charge, required equipment and personnel, etc.; — review of the standard API crane hand signals and confirmation that such hand signals will be used if radio communications are unavailable or lost; — review of the emergency stop signal and confirmation that the emergency stop can be given by anyone and must be repeated by all personnel seeing the signal; — review and confirmation that the emergency stop signal will be obeyed immediately by the crane operator (unless the emergency stop would result in a catastrophic failure of the crane); — discussion of operational or environmental conditions that can create difficulties during the crane operation; — discussion of heavy lifts or other loads that require special attention; — discussion of sea fastenings or mooring arrangements; — discussion of short service personnel or other factors that should be taken into consideration; — discussion and review of MSDS’s, if applicable I.5 Safety I.5.1 Tag lines on loads should be of an adequate length to ensure the safety of the crew on the vessel at all times The number, length, and strength of tag lines used should be appropriate for the load handled I.5.2 Pinch points and other dangers that could injure personnel handling the load should be identified I.5.3 Before the lifting operation commences, the vessel's master should ensure that cargo deck safety zones and escape routes are known to the vessel crew and crane operator I.5.4 Safety zones should be clearly defined for each vessel Such areas should be outlined with paint of a contrasting color than the rest of the deck or other visible means to enable rapid identification and should OPERATION AND MAINTENANCE OF OFFSHORE CRANES 119 remain unobstructed by loads or other material at all times Common safety areas include the forward part of the work area, aft part of the deck, and areas around fire hose stations, other fire and life safety equipment, etc I.5.5 Loading and unloading of the work deck should be planned with escape routes in mind that will afford the crew the ability to access and evacuate work areas safely These areas will vary as the amount and composition of the load changes Accordingly, escape routes should be identified prior to each lifting operation I.6 Cranes—Fitness-for-Service I.6.1 Cranes should be operated, maintained, tested, and inspected in accordance with this recommended practice and any recommendations specified by the manufacturer I.6.2 Records of periodic tests and inspections should be maintained as required in Section 5.2 and made available upon request Bibliography [1] ASME B30.5, Mobile and Locomotive Type Cranes [2] ASTM A906/A906M, Standard Specification for Forged Grade 80 and Grade 100 Alloy Steel Chain Slings for Overhead Lifting [3] ASME B30.10, Hooks [4] ASME B30.20, Below-the-Hook Lifting Devices [5] ASME B30.26, Rigging Hardware [6] Federal Specification RR-W-410, Wire Rope and Strand 120 EXPLORE SOME MORE Check out more of API’s certification and training programs, standards, statistics and publications API Monogram™ Licensing Program Sales: Email: Web: 877-562-5187 (Toll-free U.S and Canada) (+1) 202-682-8041 (Local and International) certification@api.org www.api.org/monogram API Engine Oil Licensing and Certification System (EOLCS™) Sales: Email: Web: 877-562-5187 (Toll-free U.S and Canada) (+1) 202-682-8041 (Local and International) eolcs@api.org www.api.org/eolcs API Quality Registrar (APIQR™) • • • • • • • • ISO 9001 ISO/TS 29001 ISO 14001 OHSAS 18001 API Spec Q1® API Spec Q2™ API QualityPlus™ Dual Registration Sales: Email: Web: 877-562-5187 (Toll-free U.S and Canada) (+1) 202-682-8041 (Local and International) certification@api.org www.api.org/apiqr API Training Provider Certification Program (API 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